Method of making bottle closures



May 26, 1953 Filed March 22, 1948 R. SONNENBERG METHOD OF MAKING BOTTLE CLOSURES 2 Sheets-Sheet l INVENTOR.

BY a

7MCW M W ATTYS.

y 6, 1953 R. SONNENBERG METHOD OF MAKING BOTTLE CLOSURES Filed March 22, 1948 2 Sheets-Sheet 2 W IQVENTOR. BY

7mm M W ATTYS'.

Patented May 26, 1953 METHOD OF MAKING BOTTLE CLOSURES Rudolph Sonnenberg, Belvidere, Ill., assignor to Mid-West Bottle Cap 00., Belvidere, 111., a corporation of Illinois Application March 22, 1948, Serial No. 16,207

15 Claims.

This invention relates to bottle closures and more particularly to a method ofmaking metallic foil bottle caps having an ornamental or informative indicia formed by the foil and contrasting colors imprinted directly on the foil.

In prior methods of printing on foil special equipment has had to be utilized and the result has been that the cost of printing has not been on a competitive basis with that of printing on paper. In the bottle cap industry where literally millions of bottle caps are used. it is important that the cap be relatively inexpensive. Caps must be produced at a fraction of a cent per cap.

Accordingly, the invention is concerned with a method of making dairy bottle caps oi metal foil in an inexpensive manner so thatcaps oiv this character are readily available to small, as well as large users at a relatively small-per unit cost.

Another object of the invention is to provide a method of making an article from foil wherein either a single or a plurality of colors are printed directly on untreated metal foil.

Another object of the invention is to provide a method of making metal foil caps of the above character in which the cap is formed, stacked and packaged regardless of the condition or the printing ink.

Another object of the invention is to provide a method of making metal foil caps of the above character in which the cap is formed, stacked and packaged in a, continuous process beginning with the blank foil and ending with the cap stacked in a nested relation at a capping station without manual handling during the process.

An important object of the invention is the provision of a method of producing dairy bottle caps from foil wherein adecorated cap is produced from stock material through a continuous succession of steps to the finished cap ready for immediate packaging without substantial intervening delay.

Another object of the invention is the provision of a method whereby foil hood caps for dairy bottles are made and packaged at substantiall lower cost than has heretofore been possible.

Another object is the provision of a method of making metal foil caps for dairy bottles in a continuous succession of steps wherein inked decorative or other characters are applied directlyto the surface of stock foil during the course of the process, and wherein the caps may beirnmediately packaged in stacked relation.

Other objects and advantagesof the invention will become apparent from the following detailed description taken in connection with the accompanying drawings, in which Figures 1 and 2 are schematic views showing the various steps in making a bottle closure in accordance with the invention, Fig. 2 showing apparatus for conducting the final steps of the method;

Fig. 3 is a sectional view taken through the printing mechanism showing in somewhat exaggerated form the step of impressing and printing;

Fig. 4 is a fragmentary View through the blanking and forming die mechanism showing an intermediate position of the parts in the step of forming a cap;

Fig. 5 is a fragmentary view partly in section showing the stacking step;

Fig. 6 is a view on the line 6--6 of Figure 1 showing the manner in which the stack is fed;

Fig. 7 is a fragmentary view partly in section showing the manner in which the caps are stacked or nested in the package, and

Fig. 8 is a perspective view showing caps in stacked form.

The first step in the method is that of feeding the foil from a source of supply into a position for forming recessed characters on the surface of the foil which ultimately forms the outer surface of the cap. The precise nature of this feeding step will, ofcourse, vary depending upon 7 the shape of the stock, and the apparatus to be employed will likewise vary depending upon whether-the stock is in the form of separate sheets of approximately the size required for a cap, in the form of wide rolls for the simultaneous formation of a plurality of caps, or in roll strip-form.

Forpurpose of illustration I have shown the stock in the form of a strip of approximately the width required for the formation of a cap, and have likewise shown suitable apparatus for conducting the steps of the method on material of such strip form, although it will be recognized that the apparatus will vary greatly where the stock is in other form.

In the example illustrated, the roll of stock I5 is carried on a spindle I! for free rotation thereon. The strip I5 passes from the roll over a pair of tension rolls I8 and I9, across female die members 2] and 22 of a drawing and print ing mechanism designated generally by the numeral 23, through a pair of feed rolls 24 and 26, and thence into a blanking and forming mechanism designated generally by the numeral 27. Feeding movement of the strip is in this instance produced by intermittent rotation of the feed rolls 24 and 26, and the strip is held in taut condition across the female die members by action of the tension rolls. In this instance the feed rolls and the tension .roll l8 are located below theplane 'of the female die members to hold the strip against the dies.

The foil strip l may be a strip of plain untreated metal foil (preferably aluminum because of its workability and the fact that' it fc'ari safely be used with milk) where service conditions under which the caps are to be used are not'severe, but for use where leakage is apt to occuiy'laminated foil should be used in which the laminations are foil and paper or preferably :roiran'd paper with an intermediate layer of plastic adhesive wax or the like, such as micro-crystalline wax. The laminate joiralso produces a better appearing 'cap because thdplas eyes re dily distorts to'f'ollowthe "shagiejbf the yp" giv h r' 'e a G er A l Furthermoregthefpaper assists in" etainingwhe characters in their original form-wheritli cap is'in service. V I v The second step of the method 'consists' inimpressing and printing into the foil strip where st nm riag f is "empl e in tho at spaced intervals, decorative" and informative characters whichareto appear 'on the outer surface of the mouth-spanningportion of the cap. In this stepfthe desiredindicia are impressed into the"s'trippby a drawing operation which sets the design below 'the'surround in g'outer surface of the cap and applies a coating or coatings of inkinsuitablecolors'in the depressions thus formed. Ihaveiound that thiscan bedone by a'coinbined drawing and printing operation and by means of convntional'stereotype or zinc 'platesf Suitable apparatus for carrying out this step is shown diagrammatically in Figs. 1 and 3 andjcomprisesaplaten 28'which serves to support the female die members 2| and 22, a cylinder 29 which is mounted for rotation about its axis for the purpose of inkin'gthe die plate, and also'for linear movement toward and away from the platen for impressing and' printingindicia on the strip. Disposed onith e' cylinder in side by side relationship spaced'long'itiidinally of the cylinder is a pairrof jinale' drawing and printing dies 3i and'32, "These dies are spaced on the cylinder a distance equal to that between the centers of'successive caps so that upon a single downward movement of the cylinder two difierent parts of the indicia may be formed "or rinted on successive caps and printing fnay be accomplished in diiferent colors. The number of dies may bemultipli'e'd asdes'ird "reduired.

The cylinder 291s driven its linear movefment towardandawayfrom-the platen in timed jielation to the intermittent rotation of'the feed *rollsso' that thefe'ed rolls andthefst'ri'p are stationary when the stripis engagedby 'thedie's 3l"a1 1d 32, and cancerous and strip inove'forward to bring the center of thportion' acted .upon by the die 3 l into nent'ered relationship with the die 32 whilfthe cylinder moves up and rotates in aninking stroke.

' The female die members 2! and22are formed of relatively :movable materialcapable' of :receiving and retaining the shape characteristics of the 'male diessuch that "when the male dies 3| vsand 32 are brought against'them un'der relatively highpress'ure; theimaledies forinfitherein a complementary die impression. A suitable material roller Sfi fromeach compartment of the fountain,

which in turn transfers th ink to the cylinder 2?) on which it s'spread by a pair of doctor rolls '31, these doctor'rollers passing over the surface ofth'e male die' members 3| and 32 so as to provide a coatingof ink over their outer surface, which in turn is transferred to the surface of the foil at thbottom of the depressions formed by the dies. It will therefore be seen that the surface of the foilis'simultaneously recessed and printed or inked inthe area Of'the recesses, therecessed and printed'iarea' of the strip'later forming the mouth-spanning: portion of the cap. Themale die members 31 and 32 comprise ordinary stereotype plates or'zinc etched plates such as commonly used in theip'rinting industry. The stereotype plats'are madeb'y producing a mat from-conventional type: and thereafter pouring lead against themat to form the die members 3! and 32. The zinc etched plates can be made in the conventional manner. Where the dies are to be used for particularly long runs, that is, for the manufacture of a large number of caps of similar character, the surfac of the die plate may be chr0- mium plated to increase its life and retard abrasion. An important phase of the invention lies in the use of dies of. this character for the purpose of simultaneously forming and printing the desired impressions; because such dies are quite inexpensive and may be used where only a relatively small number of caps of each design is to be manufactured without having the die cost become prohibitive. V

The nextstep in the method is that of feeding the impressed and printed foil to the forming mechanism. In this instance the strip l5 passes between the feeding rollers '24 and 26- which, as previously stated, are rotated intermittently and in timed relation to the operation of the cylinder 29. The feed rollers are located directly above and in close proximity to the die mechanism 21 and are so shaped that the strip of foil may pass therethrough without contact of the rollers with the printed portion of the strip. In this instance this is accomplished as shown in Fig. 6 by forming the cylinder 24 with a smooth cylindrical surface. and providingthe cylindrical surface of the roller'26 with an annular recess 38, this recess being formed intermediate the ends of the rolls and being of a width such that the central portion of the strip may pass between the rolls without contacting the roll 26. The end portions of the roll 26 ride against the foil strip adjacent its side edges as shown at 39 and 4| and pressure is applied to the strip between the rolls in this area sufficient to produce the action of withdrawing foil from the roll [6 and suflicient to'feed the strip I5 downwardly into the forming mechanism. It will be seen that in this step the printed strip is fed into the forming mechanism while the ink is still wet and insuch manner that the impressions or characters formed in'the strip are not disturbed.

The. nextstep in the method is that of blanking the cap blank from the strip and forming the cap. The specific construction of the blanking and forming mechanism will, of course, vary considerably depending on the shape of the cap being manufactured, the important thing being that the mechanism be so designed that the dies do not obliterate the depressed characters or smear the ink. One suitable form of mechanism is shown in Figs. 1 and 4, which includes a stationary blanking die 42 across the face of which the strip i5 is fed by action of the feed rollers. A male blanking die 43 cooperates therewith to sever the cap blank from the strip and to retain the blank by pressing the periphery thereof against the forward edge of a female skirt forming die 44. The die mechanism is operated in timed relation with the feed rolls 24 and 2B, which latter act to feed the strip down a preselected amount at each operation to bring the recessed and printed portion of the strip into central relationship with the die mechanism.

The die mechanism is shown in Fig. 4 in the position occupied by the parts prior to the completionv of the forming stroke and just before the male skirt forming die 45 moves into seated position with respect to the female skirt formingportion 44. The female die has a die element 46 cooperable with a die element 41 to form the annular rim-engaging portion of the cap. Disposed within the male die element 41 is a retainer plate 48 cooperable with a retainer member 49 of the female die element to initially grasp the strip as it is fed down by the rolls and hold it in proper aligned relationship during the blanking operation and the preliminary forming steps. The retainer member has a central recess as shown at 5i for the purpose of spacing the member from the surface of the foil so that the die mechanism does not contact the printed face of the foil during the forming operation. The retainer plate 48 is spring pressed outwardly by a spring 52 so that when the die returns to its open position the retainer plate 48 is pushed outwardly to discharge the cap from the dies. In the specific embodiment shown, a deflector plate 50 (Figure 1) is provided through which the male die passes during the forming stroke, the strip I5 passing down on one side of the plate 50 and the finished cap being discharged by the retainer plate 48 after the male die moves back through the plate 50. It will be seen that prior to the time the parts reach the position shown in Fig. 4, the cap blank is held at its edge between the male blanking die 43 and the female skirt forming portion 44. As the dies come together the retainer plate 48 and the retainer member 49 engage the blank and hold. it near its center while the die elements 46 and 4'! come together as shown in Fig. 4. These die elements thereafter hold the blank in position While the skirt is formed by approach movement of the male and female skirt forming dies.

The preformed hood cap thus produced in this instance has a central mouth-spanning portion 53 (Fig. 7) on which the recessed and printed characters appear, an annular bottle rim-engaging portion 54 and a depending annular, partially pleated skirt 55.

The next step in the method is that of conveying the formed caps from the place of formation to a suitable point for stacking and packaging. In this instance the formed caps fall from the male forming die into a chute 56 so arranged that the cap falls upon the chute with the free or lower edge of the skirt 55 resting upon the surface of the chute, as best shown in Figure 1.

The cap slides down this chute under gravity confined in its movement by the upstanding side walls 51 of the chute, and slides off the lower end of the chute as shown at 58 with the free edge of the skirt engaging the upper surface of the belt 59 of a belt conveyer. As the belt moves forward in the direction of the arrow the cap is withdrawn from the end of the chute so that the cap rests on the belt with the lower edge of the skirt contacting the belt. For purpose of illustration, the belt conveyer in this instance is shown as comprising pulleys GI and 62 over which the belt 59 is trained, the upper reach of the belt being disposed in a trough 63 to retain the caps from accidental displacement from the conveyer.

The next and final step in the method is that of stacking and packaging the formed caps in such manner as to prevent smearin or obliteration of the characters appearing on the cap. In this operation the caps are handled entirely by the skirt portions thereof and in such manner that nothing engages the center portion of the cap which would tend to smear the ink which may still be wet. Suitable mechanism for carrying out this step is shown diagrammaticallyin Figs. 2 and 5 and comprises spaced conveyer screws 64 and 65, each of which includes a spindle 66 having a pinion gear 6'! at one end thereof driven by worm gears on a Worm shaft 68 so that the screws are driven in synchronism. The screws are spaced 9. distance sufficient to receive a cap therebetween in the manner shown in Fig. 5, and a movable belt 69 trained over portions 1| and I2 is provided below the screws for engagement by the edge of the skirt to support the caps in upright position. A chute 13 is provided so that the caps discharged from the belt 59 pass edgewise down the chute into the space between the screws 64 and 65. The screws move the caps upwardly and bring them into a central position opposite the mouth of an inclined tube 14 feeding the caps one at a time into the mouth of this tube. As a result of this feeding operation the caps accumulate in stacked relation in the tube and are moved backwardly in a stack as indicated at 15 (Fig. 2). The caps may either be removed from the tube 14 in a stack to be manually packaged, or a package 16 in the form of a paper or similar tube may be inserted into the tube 14 so that the caps are fed in a stack directly into the package 16 which only needs to be removed when filled and the end sealed to be in condition for storage or shipment.

The cap is so designed as to facilitate the above-described method of its production. As will be seen from Fig. '7, the bottle rim-engaging portion 54 of the cap is so shaped that when the caps are brought into a stack the mouth-spanning portions 53 of the caps are spaced slightly for the passage of air to facilitate the drying of the ink and also to prevent contact between the inked portions of adjacent caps and to prevent the attendant offsetting and smearing. It will likewise be seen from Figs. '7 and 8 that the shape of the pleats are such that each successive cap in the stack is rotated slightly with respect to the adjacent caps, thereby preventing the recessed portions of the characters from interfitting one with the other and thereby producing smearing or offsetting.

A feature of the invention lies in the fact that the foil is recessed and printed prior to the blanking and forming of the cap, and throughout the method the caps are fed and handled without portions in spaced relationpand holding the caps in nested relation until theink is dry.

contach' ofi' foreign bOGi'GSEHJgBJiDSt the :f-ace of thez'cap.

Another feature of the method isthat the caps are recessed; printed; iormed' and stacked or packagedin a single continuous operation without 'the necessity' for": an inter-positioned drying step and-suchthat thedrying of the ink may take place after the completed cap is in storage or during the shipment of the cap to the ultimate consumer. i

'1 claim:

11 The method ofniaking dairy bottle caps of thin metal foilwhich comprisesthe steps offorming characterson foil stock by impressing the sameinto the outer surface of the stock to a planebe-low the'surf-ace oi the stock, applying a coating-ofcolored ink to-thedepressed characters, feeding the stock to a forming station, holdin said stock. in said forming station by engagement therewith annularly ofthe inked portionsthereof, forming an annular-skirt onthe foil stock shaped toinest with adjacent caps while retaining the inkedp'ortionofthestock out ofcontactwith adjacent objects, transporting the formedcaps fromthc-iorming station to a stacking station by contact with an annular portionthereof, nesting the formed caps one upon another wit-hthe inked portion of the caps in spacedrelation, and holding the capsinnested relation until the ink is dry.

1 2. Themethod of makingdairy bottle caps of thin metal foil which comprises thesteps of forming characters onfoilwstock by impressing the same into'the outer surf-ace of thestock to a plane below thesurface-oi the stock, applying ink to the depressed characters, feeding the stock to a blanking and. forming station, blanking the stock to size" and-forming an annnlarskirt on the blank-shaped to-nest with adjacent caps by engagement with opposite-faces of the stock at annular portionsthereof surrounding-the inked-portions-thereof, nesting the formed caps-one upon anotherwith the inked portions inspaced relation; and holding the caps in nested relation until the ink is dry.

3. The methodotmaking dairy bottle. caps which comprises the steps of. feeding a strip of metal foil from a roll of stock to a drawing and printing station, forming characters on the strip in an area thereof destined to hecomethe central mouth-spanning portion of the cap by impressing the characters into the outer-surface of thestock by displacing apart of themetal to. aplane below the surface of the strip, applying ink to the recessed surfaces of. the characters during the drawing operation, feeding the recessed and printed strip from the drawing and printing stationto a blanking and forming station by contact with the edge portions thereof, blanking the cap from-said strip and forming an annular skirt on the blank shaped to nest with adjacent caps by engagement with annular portions of the strip surrounding said central inked portions thereof, nesting the caps thus formed one upon another with'the'skirt portions in contact and the central The" method of making dairy bottle caps which-comprises the steps of feeding a strip of stock material having a metal foil face to a drawing and inking station, forming characters on the strip by impressing the charactersintoflthe .foil face thereof", applyingink to-the recessed surfaces of the characters during. the drawing operation, ieeding the-recessed and inked stripto a blanking and-forming station whiletheoink is still wet .by

the strip at annular-portions thereof surroundin the imprinted: portions thereof while the ink thereon'is wetwith the imprinted portion of said strip centrally disposed ofthe mouth spanning portion. of the cap, -.transferring the formed cap I to a stacking station, and stacking said caps in arrestedrelation while. the ink is wet sothat the skirts hold the .ce'ntra'l mouth ispanning portions of edgjacentnaps in space'd relation.

' GZ The'met-hoo'. of makingrimprinted hood type 1 bottle caps tromdnetalfoili 'comprising the steps of feeding 'metallidfoil stock to a drawing and inking station, forming an. intaglio character on said foil and inking said intaglio character, the depth of the character andthe ink being below the surface of thefoilsurrounding the character, feeding said imprinted foils-while the ink is wet to atcap forming .stationblanking and forming successive reaps at said forming station in timed relationwith theimprinting of said intaglio characters; by engagement with the opposite faces of the Ystrip at annular" portions thereof surrounding the-imprinted. portions thereof to form skirted caps withzsaid character centrally disposed on the formed cap; ejecting said capfrom the cap forming sta-tion'to a stacking station and stacking the cap-s'in ashipping tube. in nested relation while the ink isstil-l wet.

7.The method of making a bottle cap from metal foil having a mouth spanningportion provided with ornamental indicia,rcompr.ising the steps of drawing the foil to form intaglio depressed'characterstherein, covering the recess of said characters with alayer of ink, reforming the caps while the ink is Wet by engaging opposite-faces of the foil at annular portions thereof surrounding said imprintediportions thereof to formskirted caps having imprinted mouth spanning portions, and nesting-the-iormed caps with the mouth-spanning portions in spaced relation for reception in apackaging tube While the ink is-Wet.

. 8.. The method of. making hood type bottle caps having. a mouth-ispanning portion and a pleated skirt from a strip of. metal foil comprising the stacking theiormed-caps with the mouth span mngportionsin spaccd relation irrespective of the condition oftheink.

. 9. The methodlofnmakinghood type bottle caps irom rnetallicioil comprising the steps of..simul- ,taneously forming recessed characters and inking the same in successive positions along a strip of foil, cutting a disk from said strip in timed relation with the forming and inking of the characters, forming a cap from said disk while the ink is undried by engaging opposite faces of the foil at annular portions thereof surrounding said imprinted portions thereof to form skirted caps having imprinted mouth spanning portions, and stacking each of said formed caps in spaced nested relation while the ink is still undried.

10. The method of making bottle caps having mouth spanning portions provided with imprinted indicia from metal foil, which comprises the steps of feeding untreated metal foil stock to an imprinting station, forming in the metal foil stock intaglio characters recessed below the surface of the metal foil stock at said imprinting station and inking said intaglio characters with slow drying ink, the depth of the characters and the ink thereon being disposed below the surrounding unrecessed portions of the metal foil stock, feeding said imprinted metal foil stock while the ink thereon is wet to a cap producing station, producing from the metal foil stock while the ink thereon is wet a cap of predetermined configuration by engaging the opposite faces of the stock at annular portions thereof surrounding said imprinted portions, and ejecting the caps thus produced from the cap producing station.

11. The method of making bottle caps having mouth spanning portions provided with imprinted indicia from metal foil, which comprises the steps of feeding untreated metal foil stock to an imprinting station, forming in the metal foil stock intaglio characters recessed below the surface of the metal foil stock at said imprinting station and inking said intaglio characters with slow drying ink, the depth of the characters and the ink thereon being disposed below the surrounding unrecessed portions of the metal foil stock, feeding said imprinted metal foil stock while the ink thereon is wet to a cap producing station, producing from the metal foil stock while the ink thereon is wet a cap of predetermined configuration by engaging the opposite faces of the stock at annular portions thereof surrounding said imprinted portions, ejecting the caps thus produced from the cap producing station, and stacking the caps while the ink is wet thereon with the recessedink portions thereof spaced from the adjacent surfaces of the adjacent caps in the stack to avoid smearing the ink while the caps are stacked.

12. The method of making hood type bottle caps from metal foil having inked indicia at their respective mouth spanning portions, which comprises the steps of feeding untreated metallic foil stock to a printing station, printing inked indicia on the stock at said printing station, feeding said printed foil stock while the ink thereon is wet to a cap blanking and forming station, blanking and forming caps from the metal foil stock at the blanking and forming station while the ink thereon is wet by engaging the opposite faces of the stock at annular portions thereof surrounding said printed portions thereof to form skirted caps having printed mouth spanning portions, and ejecting the formed caps from the cap blanking and forming station.

13. The method of making hood type bottle caps from metal foil having inked indicia at their respective mouth spanning portions, which comprises the steps of feeding untreated metallic foil stock to a printing station, printin inked indicia on the stock at said printing station, feeding said printed foil stock while the ink thereon is wet to a cap blanking and forming station, blanking and forming caps from the metal foil stock at the blanking and forming station while the ink thereon is wet by engaging the opposite faces of the stock at annular portions thereof surrounding said printed portions thereon to form skirted caps having printed mouth spanning portions, and stacking the formed caps in nested relation while the ink thereon is wet with the skirts maintaining the printed mouth spanning portions of adjacent caps in spaced relation.

14. The method of making hood type bottle caps from metal foil having inked indicia at their respective mouth spanning portions, which comprises the steps of feeding untreated metallic foil stock to a printing station, printing inked indicia on the stock with a slow drying ink at said printing station, feeding said printed foil stock while the ink thereon is wet by engaging uninked portions thereof to a cap blanking and forming station, blanking and forming caps from the metal foil stock at the blanking and forming station while the ink thereon is wet by engaging the opposite faces of the stock at annular portions thereof surrounding said printed portions thereof to form skirted caps having printed mouth spanning portions, and ejecting the formed caps from the cap blanking and forming station.

15. The method of making bottle caps from metal foil having mouth spanning portions provided with inked indicia, which comprises the steps of feeding untreated metal foil stock to a printing station, printing inked indicia on the stock with slow drying ink at said printing station, feeding said printed foil stock while the ink is wet thereon to a cap producing station, producing caps from the metal foil stock while the ink is wet thereon at said cap producing station by engaging the opposite faces of the stock at portions thereof surrounding said printed portions thereof to avoid smearing the inked indicia at said printed portions thereof, and ejecting the caps from the cap producing station.

RUDOLPH SONNENBERG.

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